Ultrasonic Vibration-Assisted Machining of Advanced Materials

Abstract

Increasing demands of advanced materials have influenced the research and development work in non-conventional machining process. Machining on high hardness and difficult-to-machine materials can be possible by using ultrasonic vibration-assisted machining (UVAM), as strength density ratios, greater hardness, superior thermal quality, electrical, magnetic, optical, and its effects vary on different range of wide varieties of advanced materials. These materials have some characteristics like specific mechanical, chemical, greater physical strength, higher temperature, and have advantages of corrosion resistance, weight savings, good stiffness behaviour, and excellent surface quality. Efficient production is possible with good quality products for various applications such as industrial, domestic, and medical purposes. UVAM is one of the finest non-traditional machining (NTM) processes with recorded different types of responses on different types of advanced materials due its high range of properties and advantages. Parametric evaluation is prime factor for influencing the material removal rate (MRR), surface roughness and other quality-related issues. Different types of abrasive sizes have given different responses on MRR in this process. When the size of SiC grains is increased, the MRR rate initially increases and decreases after some interval of time. When titanium diboride/silicon carbide is used, the pattern of MRR is different than SiC. For boron carbide, MRR is decreasing with lower grit size, whereas using silicon carbide MRR is increased. High carbon steel reflects better MRR than titanium due to higher hardness. Best results can be expected when slurry concentration and temperature is kept between 30 to 60%, 5–6°C, respectively. Also, MRR decreases with the increase in slurry concentration. Frequency and amplitude are directly proportional to MRR where frequency varies from 15,000 Hz to 25,0000 Hz lower limit to upper limit, respectively. Amplitude followed by vibration as magneto-strictive material reduces the variation in transducer strength vibration is within 0.01 to 0.06 mm range. The considered length of the tool and slenderness ratio is 25 millimetres and less than 20, respectively for optimum result. Materials having tough malleable properties, i.e. alloys of steel and stainless steel can provide satisfactory results as far as machining is concerned as compared with aluminium and its alloys. This is because of its mechanical properties and tool life. In the ultrasonic machining (USM) process, the mass of the tool has a significant role as it absorbs ultrasonic energy, which is used in operating the work piece. Reduction in the machine efficiency takes place because the longer the tool, the greater will be the over stressing of the tool, as energy gets concentrated near the tool tip.